Interlocking soundproofing block system and method

ABSTRACT

A block ( 12 ) for use in interlocking, conjoined alignment with a plurality of like blocks to form a soundproofing barrier, said block ( 12 ) comprises a) a proximal panel ( 14 ) having a proximal right side and a proximal left side; b) a distal panel ( 16 ) having a distal right side and a distal left side, said distal panel ( 16 ) being longer, at its distal left side than the respective proximal right side forming a distal panel platform; the distal panel ( 16 ) and the proximal panel ( 14 ) being immovably coupled together and wherein at least one of the proximal panel ( 14 ) and the distal panel ( 16 ) comprises at least one corrugated flute.

FIELD OF THE INVENTION

The present invention relates to the field of soundproofing panels foruse in construction of buildings.

BACKGROUND ON THE INVENTION

More than ever before we are experiencing noise disturbances in our workand personal lives. Diminishing privacy and noise pollution can affectpeace of mind, increase tension levels, interfere with communicationbetween people, and jeopardize safety in the workplace.

Two distinct soundproofing problems: 1) acoustic treatments—to improvesound travel within a room (for example, an anechoic chamber) and 2)soundproofing, such as quieting, noise mitigation, and noise control canbe used to limit unwanted noise. Soundproofing can suppress unwantedindirect sound waves such as reflections that cause echoes andresonances that cause reverberation. Soundproofing can reduce thetransmission of unwanted direct sound waves from the source to aninvoluntary listener through the use of distance and intervening objectsin the sound path. The present invention relates to “soundproofing” asopposed to the enhancement of acoustics within a room.

In other words, soundproofing is any means of reducing the soundpressure with respect to a specified sound source and receptor. Thereare several basic approaches to reducing sound: increasing the distancebetween source and receiver, using noise barriers to reflect or absorbthe energy of the sound waves, using damping structures such as soundbaffles, or using active antinoise sound generators.

Furthermore, there is the issue of sound “type”. In the acousticsindustry, “bass” is known as low frequency sound. It's the boom-boommusic sound heard in adjacent cars while driving. Likewise it is thesound of jets flying overhead near a major airport.

Bass, or low frequency sound, is the worst sound of all because itassaults from long distance. It penetrates normal building walls andceilings. While low frequencies are the largest and generally the mostpowerful sound waves, they are impossible to escape. Paradoxically, thelow frequency “bass” is what is being sought more and more in hometheaters, bands, and music systems. So effective sound abatement andsoundproofing techniques will continue to be of utmost importance.

The “volume” level of sound is measured in Decibels (dB). The frequencyof sound (bass, midrange, treble, low notes, high notes, etc) ismeasured in Hertz (Hz). The sounds that are most problematic are the lowfrequencies below 125 Hz.

The standard that measures a structure's ability to hold back sound iscalled STC (an acronym for “Sound Transmission Coefficient”) and is themost recognized and discussed sound isolation term in North America.

Building codes will dictate what STC level a building needs to have. Anew condominium/apartment/flat or town home will have to comply withthese building codes and build walls, ceilings and floors that meetthese STC requirements. Why is there still a problem? The reason is thatSTC does not measure any of the worst sound of all. It stops measuringat 125H, exactly where the most offending sound starts. Code is met butlife can still be difficult.

In terms of noise reduction or abatement means, it is of course mucheasier to head off the problem during construction than try to correctit afterward. That said, today's construction techniques do nothing toprioritize sound abatement. The best acoustic isolation methods (i.e.:rooms within rooms) are far too costly. Contrary to common usage,fiberglass, foam insulation, sound board, or extra layers of drywall dovery little to stop noise transmission. Even a poured concrete orconcrete block wall is not a very good sound barrier. Sound is verydifficult to stop and solid rigid materials actually tend to transmitsound very well.

There are several ways in which a material can absorb sound. The choiceof sound absorbing material will be determined by the frequencydistribution of noise to be absorbed and the acoustic absorption profilerequired.

Porous Absorbers

Porous absorbers, typically open cell rubber foams or melamine sponges,absorb noise by friction within the cell structure. Porous open cellfoams are highly effective noise absorbers across a broad range ofmedium-high frequencies. Performance is less impressive at lowfrequencies. The exact absorption profile of porous open cell foam willbe determined by a number of factors including the following:

-   -   Cell size    -   Torosity    -   Porosity    -   Material thickness    -   Material density

Resonant Absorbers

Resonant panels, Helmholtz resonators and other resonant absorbers workby damping a sound wave as they reflect it. Unlike porous absorbers,resonant absorbers are most effective at low-medium frequencies and theabsorption of resonant absorbers is always matched to a narrow frequencyrange.

In summary, here are the current, most commonly used materials forsoundproofing in walls, floors, and ceilings:

Panels (For Walls, Floors, and Ceilings):

-   -   Drywall (also called wallboard, plasterboard, or gypsum board),        such as Sheetrock™. An inexpensive source of mass, which may        have some effect on soundproofing.    -   Damped drywall. Drywall which incorporates a sound damping        layer; examples are QuietRock™, Supress™, and SoundBreak™.    -   Sound-deadening fiberboard (also call soundboard or acoustical        board), such as SoundChoice™ or Homasote™. Because of their low        mass, these are not the best choice for soundproofing walls, but        are sometimes useful in floors as a spacing layer if additional        mass is not needed. They do not provide damping, decoupling, or        absorption.

Mass-Loaded Vinyl (“MLV”)

MLV is a highly dense, flexible membrane sold under various brand namessuch as Acoustiblok™ and SheetBlok™. This is a good source of mass, butexpensive.

-   -   MLV can fill gaps and wrap ducts, pipes, and metal columns,        where a flexible sound barrier is needed.    -   As a layer in soundproofing walls, floors, and ceilings, there        are alternatives that are more effective and cheaper than MLV.        (Drywall is a cheaper source of mass, and Green Glue™ generally        provides better damping across all frequencies.)

Insulation

Loosely packed fiber provides some limited degree sound absorption,which is a factor in soundproofing, albeit a minor one. Standardfiberglass insulation is as effective as mineral wool, and much lesscostly. Foams give great thermal insulation but are actually poor forsoundproofing.

Sound Curtains.

While ordinary curtains or blankets won't help with soundproofing, thereare noise control curtains, which are industrial products thatincorporate a heavy layer of mass-loaded vinyl.

Damping Compound

Viscoelastic adhesive such as Green Glue™ or Decibel Drop™. Used as thedamping layer between layers of drywall, plywood, or subflooring. Thissubstance is a somewhat effective and economical noise reducer and isone of the few ways to address the low-frequency noise from music, hometheaters, construction machinery, etc.

Acoustical Sealant

Sometimes called acoustical caulk, this is important for sealing seams,to prevent sound leakage. Within conventional systems, without propersealing, the effectiveness of all the other soundproofing componentswill be dramatically reduced, as the noise will simply find its waythrough the cracks.

Hardware for Decoupling.

Includes resilient sound clips and drywall furring channel or hatchannel (sometimes confused with resilient channel, which covers anassortment of non-standard items). Correct installation of decouplinghardware is very important. Although decoupling is an effective elementof soundproofing, note that it can actually increase transmission oflow-frequency noise, by creating a new resonance chamber.

Pre-Built Units.

In addition to raw building supplies, there are also pre-built unitssuch as windows and doors engineered to be soundproof, which work verywell and can save time and money.

Insulation as a Solution

One of the oldest and most established methods for improving the soundisolation of walls is the use of insulation. It is fast, reasonablyinexpensive and easy to install. In any analysis of soundproofing, itmight be useful to first consider how sound moves from one edge of awall to the other. A typical wall will have a sheet ofdrywall/stud/drywall. The wall will have air spaces in between thestuds. Drywall is very rigidly connected to the studs. Sound waves willhit that wall, and attempt to vibrate through to the room next door (orfloor below, etc. . . . ). As such, sound can vibrate into an adjoiningroom through one of two paths: a) through the rigid drywall-stud-drywallconnection path or b) through the open drywall-airspace-drywall path.

Given this structure, insulation will only be able to affect thevibration traveling through the airspace between the studs. The rigiddrywall-stud-drywall connection is not reduced with insulation and willconduct vibration just as effectively whether insulated or uninsulated.This drawback of insulation has been confirmed by extensive laboratorytesting: low frequencies are not stopped by the addition ofinsulation—high frequencies are not reduced significantly andmid-frequencies are only reduced somewhat.

There remains a need for a soundproofing system which can adequatelyaddress these and other challenges.

It is an object of the present invention to obviate or mitigate theabove disadvantages.

SUMMARY OF THE INVENTION

The present invention provides a soundproofing barrier system which maybe installed as a wall or floor and comprises a plurality of barrierpanels said blocks.

In one aspect, the prevent invention provides a block for use ininterlocking, conjoined alignment with a plurality of like blocks toform a soundproofing barrier, said block comprising:

a) a proximal panel comprising a proximal upper edge, a proximal loweredge, a proximal right edge and proximal left edge;b) a distal panel comprising a distal upper edge, a distal lower edge, adistal right edge and distal left edge,the distal panel and the proximal panel being immovably coupled togetherin both vertical and horizontal offset thereby creating four engagementplatforms: an upper engagement platform (between proximal upper edge anddistal upper edge), a lower engagement platform (between proximal loweredge and distal lower edge), a right engagement platform (betweenproximal right edge and distal right edge), and a left engagementplatform (between proximal left edge and distal left edge) and whereinat least one of the proximal panel and the distal panel comprises atleast one corrugated flute.

In another aspect, the present invention further provides asoundproofing barrier comprising a plurality of interlocking blocks,including block one and block two, each block comprising

a) panel comprising a proximal upper edge, a proximal lower edge, aproximal right edge and proximal left edge;b) a distal panel comprising a distal upper edge, a distal lower edge, adistal right edge and distal left edge,the distal panel and the proximal panel being immovably coupled togetherin both vertical and horizontal offset thereby creating four engagementplatforms: an upper engagement platform (between proximal upper edge anddistal upper edge), a lower engagement platform (between proximal loweredge and distal lower edge), a right engagement platform (betweenproximal right edge and distal right edge), and a left engagementplatform (between proximal left edge and distal left edge), wherein atleast one of the proximal panel and the distal panel comprises at leastone corrugated flute, and wherein one engagement platform of block oneengages and overlaps (docks with) another engagement platform on blocktwo to form a conjoined connection there between.

In another aspect, the prevent invention provides a block for use ininterlocking, conjoined alignment with a plurality of like blocks toform a soundproofing barrier, said block comprising:

a) a proximal panel having a proximal right side and a proximal leftside;b) a distal panel having a distal right side and a distal left side,said distal panel being longer, at its distal left side than therespective proximal right side forming a distal panel platform;the distal panel and the proximal panel being immovably coupled togetherand wherein at least one of the proximal panel and the distal panelcomprises at least one corrugated flute.

In another aspect, the present invention further provides a method ofmaking a sound proofing barrier which comprises

aligning a plurality of interlocking blocks, starting with block one andblock two, each block comprisinga) panel comprising a proximal upper edge, a proximal lower edge, aproximal right edge and proximal left edge;b) a distal panel comprising a distal upper edge, a distal lower edge, adistal right edge and distal left edge,the distal panel and the proximal panel being immovably coupled togetherin both vertical and horizontal offset thereby creating four engagementplatforms: an upper engagement platform (between proximal upper edge anddistal upper edge), a lower engagement platform (between proximal loweredge and distal lower edge), a right engagement platform (betweenproximal right edge and distal right edge), and a left engagementplatform (between proximal left edge and distal left edge), wherein atleast one of the proximal panel and the distal panel comprises at leastone corrugated flute;joining and overlapping at least part of one engagement platform ofblock one with at least part of an adjacent engagement platform on blocktwo to form a conjoined connection there between;joining and overlapping at least part of another (as yet unengaged)engagement platform of block one with at least part of an adjacentengagement platform on block three to form a conjoined connection therebetween;joining and overlapping at least part of another (as yet unengaged)engagement platform of block one with at least part of an adjacentengagement platform on block four to form a conjoined connection therebetweenand thereafter joining and overlapping further engagement platforms, onblocks one, two, three and four and additional blocks, until a fullsurface of the barrier is created by a multitude of ship lathe-likeinterconnections of the panels.

The soundproofing barrier in accordance with the present invention:

1) Creates an interlocking, overlapped and docked arrangement of blockswhich resist sound transference. In other words, within the barrier,there are no “seams”.2) Reduces impact and airborne sound by way of a corrugation systemwithin the panels.

Without limiting the general range of applications, the blocks,barriers, systems and methods of the present invention are especiallysuited to use in walls, ceilings and floors, in residential, commercialand industrial contexts.

These and other objects and advantages of the present invention willbecome more apparent to those skilled in the art upon reviewing thedescription of the preferred embodiments of the invention, inconjunction with the figures and examples.

BRIEF DESCRIPTION OF THE DRAWINGS

The following figures set forth embodiments in which like referencenumerals denote like parts. Embodiments are illustrated by way ofexample and not by way of limitation in all of the accompanying figuresin which:

FIG. 1 is front view of a block comprising two offset panels inaccordance with one aspect of the present invention;

FIG. 2 is a front view of a two adjacent but not yet interlocked blocks,each comprising two panels;

FIG. 3 is a side view of a block comprising two offset panels;

FIG. 4 is a side view of two adjacent but not yet interlocked blocks,each comprising two panels;

FIG. 5 is side view of the two blocks of FIG. 4, but interlocked;

FIG. 6 is a front view of a four adjacent and interlocked blocks, eachcomprising two panels;

FIG. 7 is a side view, in cross-section, through a block comprising twopanels comprising corrugations and wherein one panel comprises twolayers of corrugations and is thereby thicker than the other panel,which comprises only one layer of corrugation;

FIG. 8 is a side view, in cross-section of two adjacent but not yetinterlocked blocks each comprising two panels and wherein one panel ineach block comprises two layers of corrugations and is thereby thickerthan the other panel in each block, which comprises only one layer ofcorrugation;

FIG. 9 is a side view of the two blocks of FIG. 8, interconnected;

FIG. 10 a side view, in cross-section, through a block comprising twopanels comprising corrugations and wherein both panels comprise twolayers of corrugations;

FIG. 11 is a side view, in cross-section of two adjacent but not yetinterlocked blocks each comprising two panels with two layers ofcorrugation;

FIG. 12 is a side view of the two blocks of FIG. 11, interconnected;

FIG. 13 is a side view, in cross-section, through a section of a blockcomprising one panel comprising a line of flute/corrugation with anamplitude (height) of approximately 3.5 mm and a a peak to peak distanceof approximately 7.95 mm;

FIG. 14 is a side view, in cross-section, through a section of a blockcomprising one panel comprising a line of flute/corrugation with anamplitude (height) of approximately 4.6 mm and a a peak to peak distanceof approximately 8.9 mm;

FIG. 15 is a side view of a block comprising two offset panels (offsetat one side) in accordance with one aspect of the present invention;

FIG. 16 is front view of a block comprising two offset panels (offset atone side) in accordance with one aspect of the present invention;

FIG. 17 is an end view of a wall and floor join, showing the block/panelof the present invention in operation in both places;

FIG. 18 another end view of a wall and floor join, showing theblock/panel of the present invention in operation in both places;

FIG. 19 is side view of a wall, in partial cut-away;

FIG. 20 is side view of a wall showing centre line of studs; and

FIG. 21 is a further side view of a wall showing centre line of studs.

PREFERRED EMBODIMENTS OF THE INVENTION

A detailed description of one or more embodiments of the invention isprovided below along with accompanying figures that illustrate theprinciples of the invention. As such this detailed descriptionillustrates the invention by way of example and not by way oflimitation. The description will clearly enable one skilled in the artto make and use the invention, and describes several embodiments,adaptations, variations and alternatives and uses of the invention,including what we presently believe is the best mode for carrying outthe invention. It is to be clearly understood that routine variationsand adaptations can be made to the invention as described, and suchvariations and adaptations squarely fall within the spirit and scope ofthe invention.

In other words, the invention is described in connection with suchembodiments, but the invention is not limited to any embodiment. Thescope of the invention is limited only by the claims and the inventionencompasses numerous alternatives, modifications and equivalents.Numerous specific details are set forth in the following description inorder to provide a thorough understanding of the invention. Thesedetails are provided for the purpose of example and the invention may bepracticed according to the claims without some or all of these specificdetails. For the purpose of clarity, technical material that is known inthe technical fields related to the invention has not been described indetail so that the invention is not unnecessarily obscured. Similarreference characters denote similar elements throughout various viewsdepicted in the figures.

This description of preferred embodiments is to be read in connectionwith the accompanying drawings, which are part of the entire writtendescription of this invention. In the description, correspondingreference numbers are used throughout to identify the same orfunctionally similar elements. Relative terms such as “right”, “left”“horizontal,” “vertical,” “up,” “down,” “top” and “bottom” as well asderivatives thereof (e.g., “horizontally,” “downwardly,” “upwardly,”etc.) should be construed to refer to the orientation as then describedor as shown in the drawing figure under discussion. These relative termsare for convenience of description and are not intended to require aparticular orientation unless specifically stated as such. Termsincluding “inwardly” versus “outwardly,” “longitudinal” versus“lateral”, “adjacent” and the like are to be interpreted relative to oneanother or relative to an axis of elongation, or an axis or center ofrotation, as appropriate. Terms concerning attachments, coupling and thelike, such as “connected” and “interconnected,” refer to a relationshipwherein structures are secured or attached to one another eitherdirectly or indirectly through intervening structures, as well as bothmovable or rigid attachments or relationships, unless expresslydescribed otherwise. Interconnected, as used herein, generally refers tothe relationship between the platforms and adjacent blocks. The term“operatively connected” is such an attachment, coupling or connectionthat allows the pertinent structures to operate as intended by virtue ofthat relationship. In particular, the terms “right” and “left” are usedin the claims but could easily be substituted for one another. In fact,as a panel is rotated 180 degrees in either direction, right becomesleft, as so on.

The term “shiplap” is used herein to describe the way in which one block(comprising at least two panels) engages with an adjacent block by wayof the engagement platforms which are created by the offset inengagement of the panels, relative to one another. In woodworking termsand for wooden sheathing, this term refers to the rabbeting of boards sothat the edges of each board lap over the edges of adjacent boards tomake a flush joint. Essentially, a similar principle is applied here tosoundproofing panels and wherein at least one of such panels comprises acorrugated flute. As will be clear from the description and figures, itis not required that there be four engagement platforms (forming pointsof engagement with an adjacent block). In fact there can be one, two orfour.

In the present disclosure and claims (if any), the word “comprising” andits derivatives including “comprises” and “comprise” include each of thestated integers but does not exclude the inclusion of one or morefurther integers.

The terms “an aspect”, “an embodiment”, “embodiment”, “embodiments”,“the embodiment”, “the embodiments”, “one or more embodiments”, “someembodiments”, “certain embodiments”, “one embodiment”, “anotherembodiment” and the like mean “one or more (but not all) embodiments ofthe disclosed invention(s)”, unless expressly specified otherwise.

The term “variation” of an invention means an embodiment of theinvention, unless expressly specified otherwise. A reference to “anotherembodiment” or “another aspect” in describing an embodiment does notimply that the referenced embodiment is mutually exclusive with anotherembodiment (e.g., an embodiment described before the referencedembodiment), unless expressly specified otherwise.

The terms “a”, “an” and “the” mean “one or more”, unless expresslyspecified otherwise.

The term “plurality” means “two or more”, unless expressly specifiedotherwise.

The term “herein” means “in the present application, including anythingwhich may be incorporated by reference”, unless expressly specifiedotherwise.

The term “whereby” is used herein only to precede a clause or other setof words that express only the intended result, objective or consequenceof something that is previously and explicitly recited. Thus, when theterm “whereby” is used in a claim, the clause or other words that theterm “whereby” modifies do not establish specific further limitations ofthe claim or otherwise restricts the meaning or scope of the claim.

The term “e.g.” and like terms mean “for example”, and thus does notlimit the term or phrase it explains. For example, in a sentence “thecar is coloured (e.g., red, blue or green) the term “e.g.” explains that“red, blue or green” are examples of “colour”. However, those colourslisted are merely examples of “colours”, and other colours are equallyapplicable.

The term “respective” and like terms mean “taken individually”. Thus iftwo or more things have “respective” characteristics, then each suchthing has its own characteristic, and these characteristics can bedifferent from each other but need not be. For example, the phrase “eachof two machines has a respective function” means that the first suchmachine has a function and the second such machine has a function aswell. The function of the first machine may or may not be the same asthe function of the second machine.

The term “i.e.” and like terms mean “that is”, and thus limits the termor phrase it explains.

The present invention provides a soundproofing barrier system which maybe installed as a wall or floor and comprises a plurality of barrierblocks.

In one aspect, the prevent invention provides a block for use ininterlocking, conjoined alignment with a plurality of like blocks toform a soundproofing barrier, said block comprising:

a) a proximal panel comprising a proximal upper edge, a proximal loweredge, a proximal right edge and proximal left edge;b) a distal panel comprising a distal upper edge, a distal lower edge, adistal right edge and distal left edge,the distal panel and the proximal panel being immovably coupled togetherin both vertical and horizontal offset thereby creating four engagementplatforms: an upper engagement platform (between proximal upper edge anddistal upper edge), a lower engagement platform (between proximal loweredge and distal lower edge), a right engagement platform (betweenproximal right edge and distal right edge), and a left engagementplatform (between proximal left edge and distal left edge) and whereinat least one of the proximal panel and the distal panel comprises atleast one corrugated flute.

In another aspect, the present invention further provides asoundproofing barrier comprising a plurality of interlocking blocks,including block one and block two, each block comprising

a) panel comprising a proximal upper edge, a proximal lower edge, aproximal right edge and proximal left edge;b) a distal panel comprising a distal upper edge, a distal lower edge, adistal right edge and distal left edge,the distal panel and the proximal panel being immovably coupled togetherin both vertical and horizontal offset thereby creating four engagementplatforms: an upper engagement platform (between proximal upper edge anddistal upper edge), a lower engagement platform (between proximal loweredge and distal lower edge), a right engagement platform (betweenproximal right edge and distal right edge), and a left engagementplatform (between proximal left edge and distal left edge), wherein atleast one of the proximal panel and the distal panel comprises at leastone corrugated flute, and wherein one engagement platform of block oneengages and overlaps (docks with) another engagement platform on blocktwo to form a conjoined connection there between.

In another aspect, the prevent invention provides a block for use ininterlocking, conjoined alignment with a plurality of like blocks toform a soundproofing barrier, said block comprising:

a) a proximal panel having a proximal right side and a proximal leftside;b) a distal panel having a distal right side and a distal left side,said distal panel being longer, at its distal left side than therespective proximal right side forming a distal panel engagementplatform;the distal panel and the proximal panel being immovably coupled togetherand wherein at least one of the proximal panel and the distal panelcomprises at least one corrugated flute. In one aspect, the proximalleft side and the distal left side are aligned or flush. In anotheraspect, the proximal left side and the distal left side are offsetcreating an additional engagement platform (either proximal or distal).

In another aspect, the present invention further provides a method ofmaking a sound proofing barrier which comprises

aligning a plurality of interlocking blocks, starting with block one andblock two, each block comprisinga) panel comprising a proximal upper edge, a proximal lower edge, aproximal right edge and proximal left edge;b) a distal panel comprising a distal upper edge, a distal lower edge, adistal right edge and distal left edge,the distal panel and the proximal panel being immovably coupled togetherin both vertical and horizontal offset thereby creating four engagementplatforms: an upper engagement platform (between proximal upper edge anddistal upper edge), a lower engagement platform (between proximal loweredge and distal lower edge), a right engagement platform (betweenproximal right edge and distal right edge), and a left engagementplatform (between proximal left edge and distal left edge), wherein atleast one of the proximal panel and the distal panel comprises at leastone corrugated flute;joining and overlapping at least part of one engagement platform ofblock one with at least part of an adjacent engagement platform on blocktwo to form a conjoined connection there between;joining and overlapping at least part of another (as yet unengaged)engagement platform of block one with at least part of an adjacentengagement platform on block three to form a conjoined connection therebetween;joining and overlapping at least part of another (as yet unengaged)engagement platform of block one with at least part of an adjacentengagement platform on block four to form a conjoined connection therebetweenand thereafter joining and overlapping further engagement platforms, onblocks one, two, three and four and additional blocks, until a fullsurface of the barrier is created by a multitude of ship lathe-likeinterconnections of the panels.

With the scope of the present invention, regardless of shape of panel,size of panel or panel orientation: 1) one block is inter-connectable toother blocks in either an overlapping or a ship-lap like manner and 2)to achieve this, the offset of the constituent panels creates at leastone, preferably two and most preferably a plurality of engagementplatforms (for example, four per block), as described further herein.The “offset” of the panels may be horizontal, vertical or bothhorizontal and vertical, the latter dual offset creating four engagementplatforms for interconnection of one block to adjacent blocks. Asdepicted in the description and figures, the blocks each preferablycomprise two panels and at least one of these panels comprise at leastone corrugated flute.

There is no requirement that one panel in a block be the same depth asanother panel in the block. In fact, in one embodiment, one panel in ablock may be double or triple the depth of a second panel in that sameblock. In this way, and with greater depth, one panel may comprise morethan one layer of corrugated flutes.

Turning to FIG. 1, there is provided generally at 10 a single block 12for use with a plurality of other blocks in a uniquely interlockingsoundproofing barrier system. Such a system may be used in walls, flooror ceilings, as desired. While it is preferred that the panels aresubstantially rectangular, other shapes and configurations (such assquare) are certainly within the scope of the present invention. Some ofthe figures (for example FIGS. 1, 2 and 6) depict the blocks with the“length” of the rectangular panel oriented vertically. It is; however,preferred in situ that the “length” of the rectangular panel be orientedhorizontally.

Block 12 comprises proximal panel 14 and distal panel 16, both panelsbeing immovably coupled together in both vertical and horizontal offsetthereby creating four engagement platforms: an upper engagement platform18 (between proximal upper edge and distal upper edge), a lowerengagement platform 20 (between proximal lower edge and distal loweredge), a right engagement platform 22 (between proximal right edge anddistal right edge), and a left engagement platform 24 (between proximalleft edge and distal left edge).

FIG. 2 depicts block 12 adjacent to but not yet interconnected withblock 26. It is apparent that as the blocks are moved into proximity,right engagement platform 22 of block 12 will engage by sliding underleft engagement platform 28 of block 26. Such interconnections ordocking, as shown further in FIG. 6, may involve more than one blockengaging adjacent blocks.

FIGS. 3 to 5 illustrate the alignment and interconnection of block(s)from a side view. In FIGS. 3 and 4, proximal panel 30 and distal panel32 are offset forming platform A and platform B. An adjacent blockcomprises proximal panel 34 and distal panel 36 which are offset formingplatform C and platform D. In FIG. 5, it can be seen that platform C andplatform B have been slid into interconnection or “docking” with eachother.

FIG. 6 shows the interconnection or docking of four blocks, 38, 40, 42and 44 to form soundproofing barrier generally indicated at 45. Withinthe scope of the present invention, it is not required that each blockalign, end to end with its adjacent counterpart. Such is illustrated inFIG. 6, in which block 40 (with ends 46 and 48 and sides 50 and 52) isengaged on side 50 with blocks 38 and 42 and on end 48 with block 44. Itis preferred that a block align, on at least two of its four sides, withmore than one adjacent block.

The preferred off-set, ship-lap like arrangement creates strength in theconnection, a greater seal formation and concomitantly, with the furthercorrugation feature of the invention, provides the enhancedsoundproofing barrier properties.

It is preferred that at least one of the proximal panel and the distalpanel comprises at least one corrugated flute. FIGS. 7 through 12 depictvarious corrugation embodiments. In one aspect, the corrugations inpanels 14 and 16 are of the same height (amplitude) and frequency. In afurther aspect, as shown in FIGS. 7 through 9, a proximal panel 54comprises one layer of corrugated flutes and distal panel 56 comprisestwo layers (60 and 62) of corrugated flutes (a 1:2 ratio). It is equallypossible that other differentials may be used (1:3 or 1:4, for example),as desired. It is preferred that in the occasion that two or morecorrugated flutes are included within a panel, that one or moreseparator sheets 64 are disposed there between. A separator sheet mayalso be included as backing even if only one layer of corrugated flutesis selected for use.

FIG. 8 shows the alignment of proximal panel 54 and distal panel 56 justprior to docking with proximal panel 72 and distal panel 70 of block 68.The offset alignment of proximal panel 54 and distal panel 56 createsplatform E and likewise the offset alignment of proximal panel 70 anddistal panel 72 creates platform F. Platforms E and F define the dockinginterconnection as depicted best in FIG. 9.

In FIG. 10, proximal panel 74 and the distal panel 76 each comprises twolayers of corrugated flutes or waves 66. Each layer is separated from itadjacent layer by at least one separator sheet 64.

FIG. 11 shows the alignment of proximal panel 74 and distal panel 76just prior to docking with proximal panel 78 and distal panel 80 ofblock 82. The offset alignment of proximal panel 74 and distal panel 76creates platform G and likewise the offset alignment of proximal panel78 and distal panel 80 creates platform H. Platforms G and H define thedocking interconnection as depicted best in FIG. 12.

As can be seen in the figures, it is preferred that the interior of eachpanel comprises a corrugated laminar material, which defines a pluralityof corrugations or waves 66, most preferably waves that extend in adirection substantially linear and parallel to one another. Preferably,the linear waves present regular shapes and dimensions. For example,each wave 66 has a length approximately the same as its height oramplitude, advantageously wherein length and height are approximatelybetween 4 mm and 10 mm. Alternatively, the height and length of a wavemay differ, for example a length of between approximately 6 mm and 12mm, preferably between 8 mm and 10 mm, and a height between 3 mm and 6mm, preferably between 4 mm and 5 mm. By increasing or reducing theamplitude and the height of said waves 66, it is possible, respectively,to reduce and increase the strength of the base structure 10. It is mostpreferred that flute type A be used. This is an industry understoodterm.

To illustrate, FIG. 13 is a side view, in cross-section, through asection of a block comprising one panel 83 comprising a line offlute/corrugation 84 with an amplitude 87 (height) of approximately 3.5mm and a peak to peak distance 88 of approximately 7.95 mm and FIG. 14is a side view, in cross-section, through a section of a blockcomprising one panel 85 comprising a line of flute/corrugation 86 withan amplitude (height) of approximately 4.6 mm and a a peak to peakdistance 89 a of approximately 8.9 mm.

It is most preferred that corrugated flutes separated by a separatorsheet, and wherein disposition of the flutes relative to one another issuch that a trough on one flute is aligned with a peak on an adjacentflute and likewise a peak on one flute is aligned with a trough on anadjacent flute, thereby forming a plurality of alignment points 82 (FIG.12). Furthermore, this preferred arrangement creates a plurality ofchannel spaces between the flutes and the sheet. It is preferred thatthe channel spaces are filled with filler, more preferably a particulatematerial. The particulate material may preferably be selected from thegroup comprising sand (preferably fine silica sand), gravel, industrialsand, stone powder, etc. . . . . In a most preferred embodiment, thefiller is fine (washed and dried) silica sand with a US mesh of between100 (0.152 mm) and 140 (0.104 mm). Generally, the finer theparticularity or granularity of the filler, the better for use herein.Generally, the tighter the channels are packed with the filler, thebetter for use herein.

FIG. 15 is a side view of a block (shown generally at 91) comprising twooffset panels proximal panel 90 and distal panel 92 (offset at one side)in accordance with one aspect of the present invention. The offset(distal panel 92 being longer than proximal panel 90) creates distalengagement platform 94. FIG. 16 is front view of block 91.

FIG. 17 is an end view of a wall and floor join (shown generally at 95)with:

Steelstud 96 Drywall 97

Soundproofing wall block 98 (comprising panels 99 and 100, ⅝″/15 mm)Soundproofing floor block 102 (comprising panels 104 and 106, ⅝″/15 mm)Soundproofing floor block 107 (comprising panels 108 and 110, ⅝″/15 mm)Shiplap between block 102 and 107 (1.5″ reference to size of engagementplatform) Concrete Floor 115

FIG. 18 is an end view of a wall and floor join (shown generally at 114)with:

Woodstud 116 Drywall 97

Soundproofing wall block 98 (comprising panels 99 and 100, ⅝″/15 mm)Soundproofing floor block 102 (comprising panels 104 and 106, ⅝″/15 mm)Soundproofing floor block 107 (comprising panels 108 and 110, ⅝″/15 mm)Shiplap between block 102 and 107 (1.5″ reference to size of engagementplatform)

Plywood 118.

FIG. 19 is side view of a wall (shown generally at 120), in partialcut-away wherein a plurality of studs 122 (for example, woodstuds) areexposed beneath a plurality of panel/blocks 124 of the presentinvention. Panels 124 are partially exposed beneath drywall 126. Withthe North American building standards, there are 16″ between each stud(distance shown as 127). FIG. 19 depicts that, for panels of the presentinvention having a 2′×4′ dimension, there is overlap of four studs (A,B, C and D). FIG. 19 further shows that for a North American standarddrywall sheet size of 4′×8′, under-coverage is supplied by two 2′×4′panels/blocks. So, preferably one drywall sheet is covered by two panelswhich in turn covers four studs.

FIG. 20 is side view of a wall (shown generally at 128) having studs122, shiplap 112 and “on centre” line of stud 130 (shown as stippledlines running down each stud). This figure illustrates that thepreferred 48″×24″ panel/block of the present invention extends fromcentre line 130 of one stud to centre line 130 of the adjacent stud.

FIG. 21 is a side view of a wall (shown generally at 132) having studs122, shiplap 112 and “on centre” line of stud 130 (shown as stippledlines running down each stud). This figure further illustrates that thepreferred 48″×24″ panel/block of the present invention extends fromcentre line 130 of one stud to centre line 130 of the adjacent studacross 16″ distance between two centre lines (127).

It is preferred that each panel is sealed on all edges. Furthermore, itis preferred that each panel has a thickness of from 5 mm to 30 mm.Furthermore, it is preferred that each is sealed by cardboard sheets,most preferably a 1 mm (420 gr/m2) cardboard sheet. In an overallpreferred embodiment, the corrugations (waves) and separator sheets aremade of cardboard.

The number of layers and the thicknesses of each layer of fluting willbe selected by one skilled in the art depending on the desired verticalstrength required in the final corrugated product, and the capacity forsound damping required, etc. . . . . It is more than clear that someapplications (for example heavy industrial may require that each panelcomprise a plurality of corrugation layers).

It is preferred that the panels are coated with a barrier coating.Preferably, at least one panel is coated with a multi-function barriercoating, for example: Spectra-Guard 763A or Spectra-Guard 763A-Flexo orlike coatings.

Throughout the above disclosure, it is described that a block comprisestwo panels, immovably joined. In another aspect, however, these “panels”may actually be one integral unit, formed with the 1-4 engagementplatforms. So, in this aspect, the proximal panel and distal panel areseamless and integral or “one unit” divided into layer of corrugations.

In another aspect, more than two adjacent panels are joined to form ablock. It is contemplated that, within such a block, panels may beattached together by any conventional joining means (for example, glue,nails, other sealers) but, at the periphery, there are engagement panelsfor overlapping for shiplap-like attachment to adjacent blocks.

The present invention also provides a method of making a sound proofingbarrier which comprises

aligning a plurality of interlocking blocks, starting with block one andblock two, each block comprisinga) panel comprising a proximal upper edge, a proximal lower edge, aproximal right edge and proximal left edge;b) a distal panel comprising a distal upper edge, a distal lower edge, adistal right edge and distal left edge,the distal panel and the proximal panel being immovably coupled togetherin both vertical and horizontal offset thereby creating four engagementplatforms: an upper engagement platform (between proximal upper edge anddistal upper edge), a lower engagement platform (between proximal loweredge and distal lower edge), a right engagement platform (betweenproximal right edge and distal right edge), and a left engagementplatform (between proximal left edge and distal left edge);wherein at least one of the proximal panel and the distal panelcomprises at least one corrugated flute;joining and overlapping at least part of one engagement platform ofblock one with at least part of an adjacent engagement platform on blocktwo to form a conjoined connection there between;joining and overlapping at least part of another (as yet unengaged)engagement platform of block one with at least part of an adjacentengagement platform on block three to form a conjoined connection therebetween;joining and overlapping at least part of another (as yet unengaged)engagement platform of block one with at least part of an adjacentengagement platform on block four to form a conjoined connection therebetweenand thereafter joining and overlapping further engagement platforms, onblocks one, two, three and four and additional blocks, until a fullsurface of the barrier is created by a multitude of ship lathe-likeinterconnections of the panels.

In operation, the barrier of the present invention is preferablyinstalled over studs. The term “stud” in construction refers to beams ofwood, steel or other material that form the framework of a structure.Wall studs are generally covered with drywall to form the interior wallsurfaces. Studs for walls are usually two-by-four- or two-by-six-inchwooden beams, depending on the desired width of the walls. Typically,wall studs are placed 16 inches apart. Occasionally, they are placed 24inches apart. The distance between studs is measured from the center ofone stud to the center of the next. Therefore, studs are said to be 16inches “on center.” As such, it is most preferred that the blocks of thepresent invention be of a size to extend from one stud to an adjacentstud. Once in situ, for walls the barrier may further be covered by drywall paneling, as desired.

It has been found that the creation of a barrier with a combination ofadaptive micro level (preferred flute arrangement) and macro level(interlocking/docking platforms) innovations results in a superior yeteasily installable product. The barrier so created is cost effective,relatively lightweight and space effective. It can be installed byconventionally trained construction labour, using conventional tools andwith a minimum of special training. The “seal” arrangement created bythe docking engagement platforms (and preferably wherein one blockaligns, on at least two of its four sides, with more than one adjacentblock) creates a highly advantageous “non-leaky” sound barrier systemwhich has not been achieved by any other prior products.

While the forms of panels, blocks, barrier, method and system describedherein constitute preferred embodiments of this invention, it is to beunderstood that the invention is not limited to these precise forms. Aswill be apparent to those skilled in the art, the various embodimentsdescribed above can be combined to provide further embodiments. Aspectsof the present panels, blocks, barrier, method and system (includingspecific components thereof) can be modified, if necessary, to bestemploy the panels, blocks, barrier, method and system of the invention.These aspects are considered fully within the scope of the invention asclaimed. For example, the various methods described above may omit someacts, include other acts, and/or execute acts in a different order thanset out in the illustrated embodiments.

Further, in the methods taught herein, the various acts may be performedin a different order than that illustrated and described. Additionally,the methods can omit some acts, and/or employ additional acts.

These and other changes can be made to the present systems, methods andarticles in light of the above description. In general, in the followingclaims, the terms used should not be construed to limit the invention tothe specific embodiments disclosed in the specification and the claims,but should be construed to include all possible embodiments along withthe full scope of equivalents to which such claims are entitled.Accordingly, the invention is not limited by the disclosure, but insteadits scope is to be determined entirely by the following claims.

1. A block for use in interlocking, conjoined alignment with a pluralityof like blocks to form a soundproofing barrier, said block comprising:a) a proximal panel comprising a proximal upper edge, a proximal loweredge, a proximal right edge and proximal left edge; and b) a distalpanel comprising a distal upper edge, a distal lower edge, a distalright edge and distal left edge, the distal panel and the proximal panelbeing immovably coupled together in both vertical and horizontal offsetthereby creating four engagement platforms: an upper engagement platformbetween the proximal upper edge and the distal upper edge, a lowerengagement platform between the proximal lower edge and the distal loweredge, a right engagement platform between the proximal right edge anddistal right edge, and a left engagement platform between the proximalleft edge and distal left edge; and wherein at least one of the proximalpanel and the distal panel comprises at least one corrugated flute. 2.The block of claim 1 wherein both the proximal panel and distal panelcomprise at least one corrugated flute.
 3. The block of claim 1 whereinboth the proximal panel and distal panel comprise at least twocorrugated flutes.
 4. The block of claim 1 wherein both the proximalpanel and distal panel comprise three corrugated flutes.
 5. The block ofclaim 1 comprising corrugated flutes separated by a separator sheet, andwherein disposition of the flutes relative to one another is such that atrough on one flute is aligned with a peak of an upper or lower adjacentflute and a peak on one flute is aligned with a trough on an upper orlower adjacent flute, thereby forming a plurality of discrete channelspaces between the flutes and the sheet.
 6. The block of claim 5 whereinthe plurality of discrete channel spaces are filled with a filler. 7.The block of claim 5 wherein the plurality of discrete channel spacesare filled with a particulate material.
 8. The block of claim 5 whereinthe plurality of discrete channel spaces are filled with a fillerselected from the group consisting of sand, gravel, . . . .
 9. The blockof claim 5 wherein the plurality of discrete channel spaces are filledwith dried silica sand.
 10. The block of claim 1 wherein each panel issealed on all edges.
 11. The block of claim 1 wherein each panel has athickness of from 5 mm to 30 mm.
 12. The block of claim 1 wherein eachcorrugation is the same height and shape.
 13. The block of claim 1wherein entirety of each panel is sealed by cardboard sheets.
 14. Asoundproofing barrier comprising a plurality of interlocking blocks,including a first block and a second block, each block comprising: a) aproximal panel comprising a proximal upper edge, a proximal lower edge,a proximal right edge and proximal left edge; and b) a distal panelcomprising a distal upper edge, a distal lower edge, a distal right edgeand distal left edge, the distal panel and the proximal panel beingimmovably coupled together in both vertical and horizontal offsetthereby creating four engagement platforms: an upper engagement platformbetween the proximal upper edge and the distal upper edge, a lowerengagement platform between the proximal lower edge and the distal loweredge, a right engagement platform between the proximal right edge anddistal right edge, and a left engagement platform between the proximalleft edge and distal left edge; wherein at least one of the proximalpanel and the distal panel comprises at least one corrugated flute; andwherein one engagement platform of the first block engages and overlapsanother engagement platform on the second block to form a conjoinedconnection there between.
 15. The barrier of claim 14 wherein both theproximal panel and distal panel comprise at least one corrugated flute.16. The barrier of claim 14 wherein both the proximal panel and distalpanel comprise at least two corrugated flutes.
 17. The barrier of claim14 wherein both the proximal panel and distal panel comprise threecorrugated flutes.
 18. The barrier of claim 14 wherein the corrugatedflutes are separated by a separator sheet, and wherein disposition ofthe flutes relative to one another is such that a trough on one flute isaligned with a peak of an upper or lower adjacent flute and a peak onone flute is aligned with a trough on an upper or lower adjacent flute,thereby forming a plurality of discrete channel spaces between theflutes and the sheet.
 19. The barrier of claim 18 wherein the pluralityof discrete channel spaces are filled with a filler.
 20. The barrier ofclaim 18 wherein the plurality of discrete channel spaces are filledwith a particulate material.
 21. The barrier of claim 18 wherein theplurality of discrete channel spaces are filled with sand or gravel. 22.The barrier of claim 18 wherein the plurality of discrete channel spacesare filled with dried silica sand.
 23. The barrier of claim 14 whereineach panel is sealed on all edges.
 24. The barrier of claim 14 whereineach panel has a thickness of from 5 mm to 30 mm.
 25. The barrier ofclaim 14 wherein each corrugation is the same height and shape.
 26. Thebarrier of claim 14 wherein the entirety of each panel is sealed bycardboard sheets.
 27. A method of making a sound proofing barrier whichcomprises: aligning a plurality of interlocking blocks, starting with afirst block and a second block, each block comprising: a) a proximalpanel comprising a proximal upper edge, a proximal lower edge, aproximal right edge and proximal left edge; b) a distal panel comprisinga distal upper edge, a distal lower edge, a distal right edge and distalleft edge, the distal panel and the proximal panel being immovablycoupled together in both vertical and horizontal offset thereby creatingfour engagement platforms: an upper engagement platform between theproximal upper edge and the distal upper edge, a lower engagementplatform between the proximal lower edge and the distal lower edge, aright engagement platform between the proximal right edge and distalright edge, and a left engagement platform between the proximal leftedge and distal left edge; wherein at least one of the proximal paneland the distal panel comprises at least one corrugated flute; joiningand overlapping at least part of one engagement platform of the firstblock with at least part of an adjacent engagement platform on thesecond block to form a conjoined connection therebetween; joining andoverlapping at least part of another as yet unengaged engagementplatform of the first block with at least part of an adjacent engagementplatform of a third engagement block to form a conjoined connectiontherebetween; joining and overlapping at least part of another as yetunengaged engagement platform of the first block with at least part ofan adjacent engagement platform on of a fourth engagement block to forma conjoined connection therebetween and thereafter joining andoverlapping further engagement platforms, on the first, second, thirdand fourth blocks and additional blocks, until a full surface of thebarrier is created by a multitude of ship lathe-like interconnections ofthe panels.
 28. The block of claim 1 wherein the panels aresubstantially rectangular.
 29. The block of claim 1 wherein one of theproximal and distal panels is thicker than the other panel.
 30. A blockfor use in interlocking, conjoined alignment with a plurality of likeblocks to form a soundproofing barrier, said block comprising: a) aproximal panel having a proximal right side and a proximal left side;and b) a distal panel having a distal right side and a distal left side,said distal panel being longer, at its distal left side than therespective proximal right side forming a distal panel platform; thedistal panel and the proximal panel being immovably coupled together andwherein at least one of the proximal panel and the distal panelcomprises at least one corrugated flute.
 31. The block of claim 30wherein the proximal left side and the distal left side are aligned. 32.The block of claim 1 wherein at least one panel is coated with a barriercoating.
 33. The block of claim 1 wherein at least one panel is coatedwith one of SPECTRA GUARD 763A and SPECTRA-GUARD 763A-Flexo.
 34. Theblock of claim 1 wherein the proximal panel and distal panel areseamless and integral.